Chuckster 7" plate mod-Update

[dkdixie]

You may have read in another post about my experience with how I mounted Chuckster 7" plate using the stock dog bowl cover.

If not, I used 1/4-20 threaded rod to hold the plate, filter, outer piece of metal and dog bowl as one unit.

The rod broke off right at the jam nut at the throttle plate. Recovered the filter but rest of the parts were last seen heading South.

The threaded rod was just not strong enough to handle the limited vibration.

This mod will solve that problem and gives a much improved seal.

Couple weeks ago, I drilled another hole, 5/16-18, approx 1/4" below Joe's on the throttle plate. Then used full threaded Grade 8 bolt to, again, hold the entire unit together. Much stronger than 1/4-20 threaded rod and probably good enough.

But, being paranoid about it breaking again, decided to redo everything.

First, as picture shows, ran a bolt through original mounting hole to block it off.
Next, with an additional blank plate from Joe, clamped them together, drilled two 5/16-18 holes through both plates, tapped throttle plate, installed 5/16 Grade 8 full threaded bolts, jam nut at throttle plate, 2" 5/16 coupler and then outer plate.
The two mounting holes are 1.5" from the original mounting hole, almost in line with the vacuum tubes.
By going 1.5" puts the nuts in the raised portion of the dog bowl
and they fit "in the groove."
Had to remove about 1/16" of the coupler so the outer plate bottoms out.




Since now using two bolts, solved another problem with much better filter seal.
Before, with dog bowl being so far off center, and only one bolt, had to use weather stripping to help seal but still had more pressure at 6 o'clock, less at 12 o'clock.
Believe me, now its sealed evenly all the way around!!



Still gives me 3/8" clearance at the gas tank.
Used a paper towel to help the picture show the clearance.



The finished product:



If you are using Chuckster's plate and stock cover with a threaded rod or a standard Grade 2 bolt, suggest you do something to make it stronger.....cause its gonna break.
Mine lasted couple thousand miles, then broke.

[cactusjack]

The problem must be the weight of the dog dish hanging on that center bolt. I have the 7" K&N housing, which is much lighter than the dog dish and have several thousand miles on it with no failure.

[dkdixie]

Originally Posted by cactusjack

The problem must be the weight of the dog dish hanging on that center bolt. I have the 7" K&N housing, which is much lighter than the dog dish and have several thousand miles on it with no failure.

Scott, I think you are exactly right.

And the fact its vertical compounds the weight & vibration issue.

With the less weight of K&N open filter, probably not a problem.

[cactusjack]

Originally Posted by "dk dixie"

Scott, I think you are exactly right.

And the fact its vertical compounds the weight & vibration issue.

With the less weight of K&N open filter, probably not a problem.

Those dog dishes are heavy! With that much weight and constant vibration, failure of that bolt is a real concern. Looks like you've engineered a better solution.

[garyo4]

Been reading here and there about different items "Chuckster" makes for our Nomads. Is there a link to his offerings so I can browse for some upgrades?
Tks,
Gary

[dkdixie]

Originally Posted by gary-o

Been reading here and there about different items "Chuckster" makes for our Nomads. Is there a link to his offerings so I can browse for some upgrades?
Tks,
Gary

Gary, Can't find the link to Joe's website, but you can email him
chuckster1_31@comcast.net

[ccmjr77]

Just ordered my Chuckster plates today.
Now I got to get the tfi and k&N ordered.

[garyo4]

Thanks Dixie, email sent.
Gary

[chuckster131]

Gary,
Email sent back your way.

Cheers
http://www.flickr.com/photos/chuckster1/sets/

Originally Posted by gary-o

Thanks Dixie, email sent.
Gary

[chuckster131]

DK,
Thanks for posting and I'm glad you have it solid now! This is what makes this website all the better. I developed this from someone wanting me to make a TFI plate for a K-N filter open style and it has evoled into a whole lot more now than before. With listening to you and others I have since upgraded the whole set-up so we won't have any problems now and will include everything needed to this mod ( - the filter ) in a kit form to do this mod.

Note: For the 1600 two set-ups are available.
* use the stock dog bowl
* use a K-N outer cover

1500's
* use a K-N outer cover
* or if you like the look of the stock dog bowl, this setup will need a 1600 stock cover instead so it will sit flat and level. The 1500 stock cover won't sit level with the new design